Home energy storage battery system

ABSTRACT

An automatic rechargeable battery control module incorporates an automatic battery control system that automatically switches from charge to discharge modes with a single relay, thereby preventing the need to manually reset a relay switch due to an over or under voltage situation. The module requires on a single power connection line connected with a single power connector on the module. Both input power to charge the battery and output power flow in and out of the single power connector and through the single power connection line. An automatic battery control circuit is coupled with a battery management system and a relay contactor is opened and closed by a signal from the battery management system. The battery management system monitors a state of charge of the battery unit as well as current flow to and from a battery unit.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part of U.S. patent applicationSer. No. 15/658,156 filed on Jul. 24, 2017, entitled Automatic ControlSystem For A Rechargeable Battery System and current pending, which is acontinuation in part of U.S. patent application Ser. No. 14/657,972filed on Mar. 13, 2015 and currently pending, which is a continuation inpart of U.S. patent application Ser. No. 13/077,136, filed on Mar. 31,2011 and issued as U.S. Pat. No. 9,000,935 on Apr. 7, 2015, the entiretyof all applications are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION Field of the Invention

The invention is directed to an automatic rechargeable battery controlmodule having a single power connector for receiving and deliveringpower through a single power connection line and that incorporates anautomatic control system.

Background

Current battery management systems obtain data about individual batteryunits in a battery system. The systems reserve addresses forcommunication with battery unit sensors and/or battery units. Whensensors transmit data about battery units to the management system, thesensors include the address of the battery unit. Such a system mayrequire significant amounts or resources and complex arrangements forconnecting the components of the system.

As shown in FIG. 19, lithium batteries have a non-linear dischargeprofile, with a relatively flat discharge region up to about 80%discharged. Therefore, a small change in voltage can mean a largedifference in the state of charge, unlike a lead acid battery that has arelatively linear drop in voltage as the battery is discharged. Thestate of charge of a lead acid battery, and therefore the amount ofpower remaining, is more easily monitored by a UPS system by simplymonitoring the voltage of the lead acid battery. The amount of powerremaining in a lithium battery system is more difficult to monitor andpredict however by simply measuring voltage. It would therefore be moredifficult to determine the available power remaining in a lithiumbattery unit by simply measuring the voltage.

Current charging systems are configured to charge a battery pack to apredetermined voltage. However, the individual battery may not becharged to the same level, and the discrepancy between the batteriesstate of charge levels can cause capacity to be limited. The batterypack capacity is limited to the capacity of the lowest battery unit.Additionally, when some battery units have lower state-of-charge levels,as the battery discharges, those units may discharge to a levelresulting in permanent loss of charging capacity.

Current battery control systems for rechargeable batteries that haveover-charge and under-charge protection features typically utilize tworelays or contactors that open to isolate the battery system in theevent of an over-charge or under-charge condition. The two relays may bein series and require a manual reset. They may use two parallel relaysin parallel and each has a diode to control flow of current to and fromthe battery. This system is complex and requires expensive components.

SUMMARY OF THE INVENTION

The invention is directed to an exemplary automatic rechargeable batterycontrol module that has a single power connector. The single powerconnector is coupled with a single power connection line that is coupledwith both a power source to provide a flow of power to the automaticrechargeable battery control module to charge the batteries and with aload that receives a flow of power from the automatic rechargeablebattery control module. This single power connector makes installationvery simple. The single power connector may be a DC connector andprovide power directly to a load, or to an inverter or power controller.A power controller may regulate power to a load and also a supply ofpower to the automatic rechargeable battery control module for chargingto the batteries. In an exemplary embodiment, an inverter or powercontroller may be configured with an automatic rechargeable batterycontrol module. In addition, an exemplary automatic rechargeable batterycontrol module incorporates an automatic control system thatautomatically switches from a charging mode to a discharging mode anddoes not require any manual resetting to switch from one mode to theother. An automatic control system may also monitor the battery orbattery pack and the state of charge to prevent overcharging or overdischarging wherein the battery pack drops below a lower threshold stateof charge.

The exemplary automatic rechargeable battery control module may beincorporated into a back-up power supply system that also utilizes analternative power source, such as a solar power generator or wind powergenerator, geothermal power generator, hydropower generator and thelike. The system may be configured to provide power to a dwelling,office building, store or factory, for example. Power produced by thealternative power supply system may be directed to the load and/or aportion may be directed through the single power connection line tocharge the batteries in the exemplary automatic rechargeable batterycontrol module. When the alternative power source is not producingpower, or is producing power below a threshold supply level, theautomatic rechargeable battery control module may provide power, throughthe single power connection line, to the load. The automaticrechargeable battery control module, as well as the alternative powersource and the load may be connected to a maximum power point tracker.MPPT, that converts the power as required for supply to the load and isan electronic DC to DC converter that optimizes the match between, analternative power source, such as a solar array (PV panels), and theautomatic rechargeable battery control module and/or utility grid. Anexemplary MPPT incorporates an algorithm and charge controllers used toextract maximum available power from alternative power source undercertain conditions. Power shaving can be accomplished with this system,wherein power produced by the alternative power supply or from the gridduring non-peak hours, is stored in the automatic rechargeable batterycontrol module and subsequently supplied by the automatic rechargeablebattery control module during peak hours, when the power rates are moreexpensive.

An exemplary automatic rechargeable battery control module may comprisea battery pack with one, but in most cases, a plurality of individualbatteries. In an exemplary embodiment, the battery pack compriseslithium ion batteries that produce about 3.0V each. An electricalarrangement of the batteries, such as in series and/or in parallel, mayprovide a 48V load or any suitable load as dictated by the application.An exemplary automatic rechargeable battery control module may beconfigured to produce a supply of power that is suitable for anapplication. For example, a small home or apartment may require about 10kW-hours or more of power a day and a larger home or office may require20 to 30 kW-hours or more of power a day. Larger apartment building mayrequire 40 or 50 kW-hours or more of power a day. An individualautomatic rechargeable battery control module may be configured toprovide about 3 kW-hr or more of power a day, about 5 kW-hr or more ofpower a day, about 10 kW-hr or more of power a day, about 20 kW-hr ormore of power a day, about 50 kW-hr or more of power a clay, and anyrange between and including the power levels provided. A plurality ofautomatic rechargeable battery control modules may be coupled togetherelectrically in parallel or in series to provide a module stack toprovide a suitable power supply for an application. For example, three10 kW-hr automatic rechargeable battery control modules may be stackedand connected in parallel to provide up to about 30 kW-hr of power to alarge home.

An exemplary automatic rechargeable battery control module is configuredwithin a housing along with one or more rechargeable batteries or abattery pack. The exemplary automatic rechargeable battery controlmodule is very simple to set up, as it has a single power connector thatmay be configured to receive the single power connection line. Thesingle power connection line may comprise an Anderson plug and thesingle power connector may be an Anderson plug connector having apositive and negative terminal. The automatic rechargeable batterycontrol module also has an on/off switch, making installation andoperation of the automatic rechargeable battery control module veryeasy.

An exemplary automatic rechargeable battery control comprises a lowvoltage disconnect, LVD, that discontinues power supply from thebatteries if the state of charge of the battery or battery pack dropsbelow a lower threshold state of charge. The automatic battery controlsystem and/or the microprocessor and sensors, may be powered by thebattery pack and this parasitic load can reduce the state of charge ofthe batteries to a lower threshold limit. The low voltage disconnectwill discontinue power from the battery pack in the event the state ofcharge drops below a lower threshold value. This prevents any damage tothe batteries from over discharging. Likewise, an exemplary automaticrechargeable battery control comprises an over voltage disconnect thatdiscontinues power supply to the batteries if the state of charge of thebattery or battery pack rises above an upper threshold state of charge.This will prevent damage to the batteries from an over voltagecondition, or over charging the batteries.

An exemplary automatic rechargeable battery control module incorporatesan automatic battery control system for a rechargeable battery systemthat enables the batteries to be switched from a charging mode to adischarging mode automatically. An exemplary automatic battery controlsystem comprises a parallel resistor configured in parallel with acontactor of the relay, or relay contactor as used herein, that isconfigured to isolate the battery from the load and/or power source orcharger. The parallel resistor has a high resistance value so verylittle current flows through the resistor but the relay potential,either positive or negative, of the parallel resistor is sensed by adifference amplifier and indicated by an optocoupler to amicroprocessor. A parallel resistor may have a resistance value thatproduces a voltage of about 0.2V between a battery and a minimum load.This 0.2V potential is then amplified by a difference amplifier. When aload is connected to the automatic battery control circuit, or batteryunit, the output side of the relay contactor and parallel resistor dropsin voltage below the voltage on the input side, or below the batteryvoltage, thereby producing a negative relay potential. When a powersource or charger is connected to the automatic battery control circuit,or battery unit, the output side of the relay contactor and parallelresistor increases in voltage above the voltage on the input side, orabove the battery voltage, thereby producing a positive relay potential.

A battery management system measures the state of charge of the batteryand has set limits for over-voltage and under-voltage. An exemplarybattery management system has an over-voltage output for providing anover-voltage output signal when the measured state of charge of thebattery is above an upper threshold limit. An exemplary batterymanagement system has an under-voltage output for providing anunder-voltage output signal when the measured state of charge of thebattery is below a lower threshold limit. The upper and lower thresholdlimits may be set to avoid damage to the battery from over dischargingor over charging, and may be factory set limits, or set by a user. Inthis system, the under-voltage output signals are ignored when in thecharging mode and the over-voltage output signals are ignored when inthe discharging mode. The system automatically switches from dischargeto charge without any manual reset and with only one relay contactor.

An exemplary automatic battery control system comprises a battery systemthat may comprise a plurality of battery units and these battery unitsmay be coupled in series or parallel. An exemplary automatic batterycontrol system comprises a microprocessor that is coupled with thebattery management system and the automatic battery control system. Themicroprocessor receives state of charge information from the batterymanagement system and provides control of a transistor that opens andcloses the relay contactor of the relay. A microprocessor also receivesinput from a first and charge optocoupler that are coupled with thedifference amplifier. The optocoupler provides input to themicroprocessor of the mode, either charging or discharging. When a loadis connected, the voltage on an output side of the relay contactor andthe parallel resistor will drop, and this drop or negative potentialacross the relay contactor from the input side to the output side, asmeasured by the parallel resistor, is sensed by the difference amplifierand indicated to the microprocessor by the discharge optocoupler. Whenin a discharge mode, the relay potential is negative indicating thatcurrent in flowing from the battery to the load, and this is provided tothe microprocessor through the discharge optocoupler. When a powersource or charger is connected, the voltage on an output side of therelay contactor and the parallel resistor will rise, and this increaseor positive potential across the relay contactor from the input side tothe output side, as measured by the parallel resistor is sensed by thedifference amplifier and indicated to the microprocessor by the chargeoptocoupler. When in a charge mode, the relay potential is positiveindicating that current in flowing to the battery, and this is providedto the microprocessor through the charge optocoupler. The batterymanagement system comprises a current flow output, a MODBUS for example,that provides a current signal to the microprocessor of the current flowdirection into and out of the battery. An exemplary battery managementsystem may be powered by an isolated power supply that may be powered bya 5V power supply that runs the system.

An exemplary automatic battery control system comprises an automaticbattery control circuit coupled to the battery management system, themicroprocessor and the battery unit. An automatic battery controlcircuit comprises a single relay having a single relay contactor andtransistor. In addition, the automatic battery control circuit parallelresistor configured in parallel with the relay contactor, from the inputside to the output side of the relay contactor.

An exemplary automatic battery control system can switch automaticallyfrom a discharge made to a charge mode. In a discharge mode, when nounder-voltage signal is received by the microprocessor from theunder-voltage output, the microprocessor will close the relay contactorby a transistor. With the relay contactor is closed, the relaypotential, as measured by the parallel resistor, will be substantiallyzero, and the output of the charge optocoupler will turn off preventingany over-voltage signals from causing the relay to be opened. The relaywill remain closed as long as the current flow output (MODBUS) providesa current signal of a current flowing to the load. When said currentsignal of a current flowing to the load stops, the microprocessor willopen the relay contactor thereby isolating the battery from the load.The microprocessor will also open the relay contactor when an upperthreshold limit is detected by the battery management system, therebypreventing over discharging of the battery unit.

In a charge mode, when no over-voltage signal is received by themicroprocessor from the over-voltage output, the microprocessor willactivate the relay contactor to close by the transistor. With the relaycontactor closed, the relay potential, as measured by the parallelresistor, will be substantially zero, and the output of dischargeoptocoupler will turn off preventing any under-voltage signals fromcausing the relay contactor to be opened. The relay contactor willremain closed as long as the current flow output (MODBUS) provides acurrent signal of a current flowing to the battery unit. When thecurrent signal of a current flowing to the battery unit stops, themicroprocessor will open the relay thereby isolating the battery unitfrom the power source or charger. The microprocessor will also open therelay contactor when an lower threshold limit is detected by the batterymanagement system, thereby preventing overcharging of the battery unit.

When the relay contactor is open, there is a high resistance between theinput and output side of the relay contactor, or the parallel resistor,and therefore a potential across the parallel resistor can be measuredby the difference amplifier. However, when the relay contactor isclosed, current will flow through the relay and there will be littlecurrent flowing through the resistor, as it is a high resistance valueresistor of 1,000 ohms or more, about 10 k ohms or more, about 100 kohmsor more, and any rage between and including the resistance valuesprovided. The resistance value of the parallel resistor is chosen toprovide a voltage potential across the resistor of about 0.2V when abattery that has a state of charge between the upper and lower thresholdlimits, or charge and discharge threshold limits, is connected to aminimum load. As long as there is no load or power source or chargerconnected to the battery unite, there is no voltage across the resistor.When the output side or output voltage of the relay contactor risesabove the battery voltage, due to connection of a power source orcharger, it will close the relay contactor to turn it on, assuming thebattery unit is below a threshold charge limit state of charge. And,when the output side or output voltage of the relay contactor dropsbelow the battery voltage, due to connection of a load, it will closethe relay contactor to turn it on, assuming the battery unit is above athreshold discharge limit state of charge. The threshold charge limitand upper threshold limits may be the same or substantially the samevalue, such as within about 5% of each other. Likewise, the thresholddischarge limit and lower threshold limits may be the substantially thesame value, such as within about 5% of each other. A threshold chargelimit may be a state of charge value that is less than an upperthreshold limit and may allow charging of the battery unit to the upperthreshold limit before the microprocessor opens the relay. A thresholddischarge limit may be a state of charge that is above a lower thresholdlimit and may allow discharging to a lower threshold limit before themicroprocessor opens the relay.

In an exemplary embodiment, a battery management system, comprises aprogram to determine the state of charge of a battery unit or battery,or the amount of available charge remaining. The calculation takes intoaccount the battery unit or pack voltage prior to the utilization ofbattery power as the output power. The program utilizes input related tothe power being drawn by the powered device, such as current, voltageand time, and calculates the total power usurped from the battery pack.The program can then calculate the discharge percent of the batterypack, as depicted in FIG. 19, A power control system may calculate thetime remaining before the battery pack is discharged 80% and may send analert via a data transmission system of the remaining time beforeshut-down. A power control system may shut-down the battery pack if adischarge level of 80% or more is reached, for example, in an effort toprotect the system and prevent damage to the battery pack.

An exemplary battery management system includes a battery unitmonitoring module that is utilized for obtaining data about batteryunits in a battery pack. A computing device can obtain the data bysending a data request to the first monitoring module. The firstmonitoring module obtains and transmits data about its connected batteryunit to the computing device and sends a data request to the secondmonitoring module. The second monitoring module obtains and transmitsdata about its connected battery to the computing device and sends adata request to the next monitoring module. Each successive monitoringmodule performs the same steps until all the monitoring modules havesent data about their connected battery units to the computing device.Thus, the computing device needs solely a data request port and inputdata port(s) to obtain the data for a battery pack.

In one aspect, the present disclosure describes a battery managementsystem. The battery management system includes a computing device withan output data request port and an input data port. The batterymanagement system also includes first and second battery unit monitoringmodules, each battery unit monitoring module connected to the input dataport of the computing device. In response to a data request from theoutput data request port of the computing device, the first battery unitmonitoring module transmits data of the first battery unit to the inputdata port of the computing device, and transmits a data request to thesecond battery unit monitoring module. In response to the data requestfrom the first battery unit monitoring module, the second battery unitmonitoring module transmits data of the second battery unit to the inputdata port of the computing device.

The first battery unit monitoring module can connect to a first batteryunit in a battery pack of an electric vehicle. The battery managementsystem can also include wiring connecting the computing device to thebattery unit monitoring modules. Because the battery units in a batterypack can be wired in series, the physical locations of the positive andnegative terminals arranged in an alternating fashion, the secondbattery unit monitoring module is oriented in an opposite direction fromthe first battery unit monitoring module.

The first battery unit monitoring module can include ananalog-to-digital converter. The analog-to-digital converter can measurea voltage of the first battery unit. The first battery unit monitoringmodule can include a temperature monitoring device that measures atemperature of the first battery unit. The temperature can be expressedas a voltage which is applied to an input of the analog-to-digitalconverter. Data of the first battery unit can be a voltage and atemperature of the first battery unit. Data of the second battery unitcan be a voltage and a temperature of the second battery unit.

The computing device can scan the first and second battery unitmonitoring modules to determine a number of battery unit monitoringmodules in the battery management system. The computing device cantransmit a second data request to the first battery unit monitoringmodule after the computing device has not received data on the inputdata port for a predetermined period of time. The predetermined periodof time may be 20 ms. The computing device can include ananalog-to-digital convertor that measures a voltage across the first andsecond battery units. The computing device can include ananalog-to-digital convertor that measures a current flowing in the firstand second battery units.

The computing device can output an alarm when an error condition isdetected. The error condition can be a high voltage condition, a lowvoltage condition, a high current condition, a high temperaturecondition, or a connection fault condition. The computing device canshut off a battery charger when the computing device detects a highvoltage condition across the first and second battery units. Thecomputing device can shut off a motor controller when the computingdevice detects a low voltage condition across the first and secondbattery units.

The battery management system can include a monitor, such as a videomonitor, that displays the data of the first and second battery units.The battery management system can include a connection fault detectorthat detects a connection between a node at a zero-voltage referencelevel and the first and second battery units. The battery managementsystem can include one or more battery unit balancing systems, eachsystem balancing charge in a battery unit.

In another aspect, the present disclosure describes a battery managementsystem with a computing device and first and second battery unitmonitoring modules. The computing device includes a first output datarequest port and an input data port. The first battery unit monitoringmodule includes a first input data request port connected to the outputdata request port of the controller, a first output data port connectedto the input data port of the controller, and a second output datarequest port. The second battery unit monitoring module includes asecond input data request port connected to the second output datarequest port of the first battery unit monitoring module, and a secondoutput data port connected to the input data port of the controller.

In another aspect, the present disclosure describes a method of managinga battery. The method includes transmitting, by a computing device, afirst data request to a first battery unit monitoring module. The methodalso includes transmitting, by the first battery unit monitoring module,data of a first battery unit to an input data port of the computingdevice in response to the first data request. The method also includestransmitting, by the first battery unit monitoring module, a second datarequest to a second battery unit monitoring module. The method alsoincludes transmitting, by the second battery unit monitoring module,data of a second battery unit to the input data port of the computingdevice in response to the second data request.

The entirety of the following patents are incorporated by referenceherein: U.S. Pat. No. 8,723,482 issued on May 13, 2014 and entitledBattery Unit Balancing System; U.S. Pat. No. 9,595,847, issued on Mar.14, 2017 and entitled Uninterrupted Lithium Battery Power Supply System;U.S. Pat. No. 9,371,067, issued on Jun. 21, 2016 and entitled IntegratedBattery Control System; and U.S. Pat. No. 9,553,460, issued on Jan. 24,2017 and entitled Wireless Battery Management System; all are assignedto Elite Power Solutions LLC.

The summary of the invention is provided as a general introduction tosome of the embodiments of the invention, and is not intended to belimiting. Additional example embodiments including variations andalternative configurations of the invention are provided herein.

BRIEF DESCRIPTION OF SEVERAL VIEWS THE DRAWINGS

The accompanying drawings are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention, andtogether with the description serve to explain the principles of theinvention.

FIG. 1 is a block diagram depicting an exemplary embodiment of a batterymanagement system connected to a battery pack.

FIG. 2 is a block diagram depicting an exemplary arrangement of batteryunit monitoring modules of the battery management system with respect tothe battery units of the battery pack.

FIG. 3 is a block diagram depicting connections within the batterymanagement system between the computing device and the battery unitmonitoring modules.

FIG. 4 is a diagram depicting connections between battery unitmonitoring modules.

FIG. 5 is a hybrid block and circuit diagram depicting an exemplarybattery unit monitoring module.

FIG. 6 is a circuit diagram of an exemplary embodiment of a battery unitmonitoring module.

FIG. 7 is a circuit diagram of an exemplary embodiment of the interfacefor a computing device.

FIG. 8 is a circuit diagram of an exemplary embodiment of a battery unitbalancing system in a battery unit monitoring module.

FIG. 9 is a block diagram depicting an exemplary embodiment of thecomputing device of the battery management system.

FIG. 10 is a block diagram depicting an exemplary embodiment of thealarm output system of the computing device.

FIG. 11 is a circuit diagram depicting an exemplary embodiment of thealarm output system of the computing device.

FIG. 12 is a block diagram depicting an exemplary embodiment of theconnection fault detection system of the computing device.

FIG. 13 is a circuit diagram depicting an exemplary embodiment of theconnection fault detection system of the computing device.

FIG. 14 is a circuit diagram depicting an exemplary embodiment of thepack voltage and pack current input systems of the computing device.

FIG. 15 is a circuit diagram depicting an exemplary embodiment of theprocessor of the computing device.

FIG. 16 is a circuit diagram depicting exemplary embodiments of powersupplies used with the battery management system.

FIG. 17 is a circuit diagram depicting an isolated power supply to powerthe circuits of FIG. 14.

FIG. 18 is a circuit diagram depicting exemplary embodiments of acontroller area network (CAN) interface.

FIG. 19 shows an exemplary discharge profile for a lithium battery.

FIG. 20 shows a diagram of an exemplary lithium battery power supplysystem.

FIG. 21 shows an exemplary power control system and a plurality ofinput, outputs and indicators.

FIG. 22 shows a top perspective view of an exemplary battery pack withbattery monitoring modules configured thereon.

FIG. 23 shows diagram of an exemplary lithium battery power supplysystem.

FIG. 24 shows an exemplary automatic battery control system diagramcomprising an automatic battery control circuit coupled with a batterymanagement system, a microprocessor, a battery unit and load.

FIG. 25 shows a diagram of a battery state of charge and the limits forcharging and discharging.

FIG. 26 shows a flow diagram of an automatic battery control system in adischarging mode.

FIG. 27 shows a flow diagram of an automatic battery control system in acharging mode.

FIG. 28 shows a perspective view of an exemplary automatic rechargeablebattery control module having a single power connector.

FIG. 29 shows a perspective view the exemplary automatic rechargeablebattery control module shown in FIG. 28 with the top removed to show theplurality of rechargeable batteries and the automatic battery controlsystem within the housing of the module.

FIG. 30 shows a schematic of an exemplary automatic rechargeable batterycontrol module connected to a MPPT, which couples the battery controlmodule with the load, a home, and a power source, a photovoltaic cell.

FIG. 31 shows a schematic of an exemplary automatic rechargeable batterycontrol module connected to load, such as a home and a alternative powersource also electrically coupled with the same load.

FIG. 32 shows a perspective view of a plurality of exemplary automaticrechargeable battery control modules stacked and electrically coupled inparallel and having a single power connector.

FIG. 33 shows a circuit diagram for an exemplary automatic rechargeablebattery control module comprising a battery pack having two parallelsets of four batteries each, and an automatic power control system.

Corresponding reference characters indicate corresponding partsthroughout the several views of the figures. The figures represent anillustration of some of the embodiments of the present invention and arenot to be construed as limiting the scope of the invention in anymanner. Further, the figures are not necessarily to scale, some featuresmay be exaggerated to show details of particular components. Therefore,specific structural and functional details disclosed herein are not tobe interpreted as limiting, but merely as a representative basis forteaching one skilled in the art to variously employ the presentinvention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a process,method, article, or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. Also, use of “a” or “an” are employed to describeelements and components described herein. This is done merely forconvenience and to give a general sense of the scope of the invention.This description should be read to include one or at least one and thesingular also includes the plural unless it is obvious that it is meantotherwise.

Certain exemplary embodiments of the present invention are describedherein and are illustrated in the accompanying figures. The embodimentsdescribed are only for purposes of illustrating the present inventionand should not be interpreted as limiting the scope of the invention.Other embodiments of the invention, and certain modifications,combinations and improvements of the described embodiments, will occurto those skilled in the art and all such alternate embodiments,combinations, modifications, improvements are within the scope of thepresent invention.

The present disclosure describes, among other things, certainembodiments of a battery management system. The management systemobtains and displays data about battery units in a battery pack. Themanagement system can monitor the voltage and temperature of theindividual battery units and/or the entire battery pack. If themanagement system discovers any of the battery units pose a concern(e.g., the voltage is over or under limits, or the battery unit isoverheating), the system can take measures to prevent damage to itselfor the battery pack or to alleviate the concern. The system can alsotake comparable measures if the system detects a connection between anyof the battery units and ground. Thus, the battery management system canmaintain the consistent operation of the system the battery pack powers,such as an electric vehicle.

Referring now to FIG. 1, a block diagram of an exemplary embodiment of abattery management system 100 connected to a battery pack 190 is shownand described. The battery management system 100 includes battery unitmonitoring modules 105 (e.g., sense boards), a computing device 110, anda display 115 (e.g. a monitor such as an LCD monitor or a monitorincorporated into another device, such as a DVD player). The computingdevice 110 can measure voltage and/or current for the entire batterypack 190 and output the data to the display 115. In various embodiments,the computing device 110 can determine the state of charge of thebattery pack 190 by measuring the amount of current that flows in or outof the battery pack 190. The battery pack 190 can integrate the amountof current to determine the state of charge. In some embodiments, whenthe battery pack 190 reaches a minimum, predetermined voltage, thecomputing device 110 can set the pack's 190 state of charge to about 0%.When the battery pack 190 reaches a maximum, predetermined voltage, thecomputing device 110 can set the state of charge to about 100%.

In some embodiments, the battery pack 190 may include a plurality ofbattery units 195 (e.g., battery cells). Each battery unit may include abattery cell or a plurality of battery cells. The battery pack 190 canconnect to an external load 198, such as a motor for an electricvehicle. Each battery unit monitoring modules 105 of the managementsystem 100 can connect to a battery unit 195. A monitoring module 105can obtain data, such as voltage and/or temperature, for the batteryunit 195 connected to the module 105. The monitoring modules 105 cantransmit the data to the computing device 110, which can output the datato the display 115.

In some embodiments, the computing device 110 may be configured tooperate with a predetermined, fixed number of battery unit monitoringmodules 105. In some embodiments, the computing device 110 may beconfigured to scan the modules 105 to determine the number of modules105 present. The computing device 110 can scan the battery unitmonitoring modules 105 to determine the number of monitoring modules 105in the system 100. For example, in some embodiments, the computingdevice 110 can output a scan signal to the first monitoring module 105.In response, the monitoring module 105 can return battery unit voltageand temperature data to the computing device 110 and can output a scansignal to a successive monitoring module 105. In some embodiments, themonitoring module 105 can also return battery unit voltage andtemperature data to the computing device 110, and can output a scansignal to the next module 105. Thus, the computing device 110 can countthe number of monitoring modules 105 by the number of voltage andtemperature data packets received. Further, the computing device 110 cannumber a monitoring module 105 and/or battery unit 195 based on themodule's 105 or unit's 195 position in the order of scan signalsreceived. In some embodiments, a user can configure the computing device110 to set the number of monitoring modules 105 or to instruct thedevice 110 to scan the modules 105 and obtain the number of modulesitself.

The computing device 110 can detect error conditions for individualbattery units 195 and/or the entire battery pack 190. Exemplary errorconditions can include conditions such as high voltage conditions, lowvoltage conditions, high current conditions, and high temperaturecondition. Another exemplary error can be a connection fault condition,e.g., a connection between at least one battery unit 195 and a contactpoint with a zero-voltage reference level, such as a chassis of anelectric vehicle.

When an error is detected, the computing device 110 can initiate ameasure based on the error condition. For example, if the computingdevice 110 detects a high voltage condition for the entire battery pack190, the computing device 110 can inactivate a device that charges thepack 190 (not shown). In another example, if the computing device 110detects a first low voltage condition, the computing device 110 canoutput a low voltage warning to the display 115. If the battery pack's190 voltage drops further, triggering a second low voltage condition,the device 110 can inactivate a load connected to the battery pack 190,such as a motor controller of an electric vehicle.

Referring now to FIG. 2, a block diagram of an exemplary arrangement ofbattery unit monitoring modules 105 and battery units 195 in a pack 190is shown and described. In this embodiment, the monitoring modules 105are connected to the battery units 195, which are connected in series.Each monitoring module 105 can be connected to a single battery unit195. The battery unit 195 can supply the connected monitoring module 105with power for performing its operations.

FIG. 3 is a block diagram depicting connections within the batterymanagement system 100 between the computing device 110 and the batteryunit monitoring modules 105. The computing device 110 includes an outputdata request port (also referred to herein as an “enable output”) and aninput data port. Each monitoring module 105 includes an output dataport, an input data request port (also referred to herein as an “enableinput”), and an output data request port. Each monitoring module's 105output data port is connected in parallel to the computing device's 110input data port.

The computing device's 110 output data request port is connected to thefirst one of the battery unit monitoring module's 105 a input datarequest port. The monitoring module's 105 a output data request port isconnected to the input data request port of the successive monitoringmodule 105 b. In turn, the monitoring module's 105 b output data requestis connected to the input data request port of the next monitoringmodule 105 c. The remaining monitoring modules 105 are connected in thesame manner. The communications of the computing device 110 and batteryunit monitoring modules 105 described herein are transmitted from andreceived at these ports, as would be understood by one of ordinary skillin the art. Further, in various embodiments, the computing device 110and monitoring modules 105 include voltage and ground connections suchthat the computing device 110 can provide power (e.g., 12V) and groundto the monitoring modules 105.

In operation, to obtain data about the battery units 195, the computingdevice 110 sends a data request signal (also referred to herein as an“enable signal” or an “enable pulse”) to the first battery unitmonitoring module 105 a. In response, the monitoring module 105 atransmits data about a connected battery unit 195 a to the computingdevice 110. After the module 105 a finishes transmitting data, themodule 105 a sends a data request signal to the second battery unitmonitoring module 105 b. In response, the monitoring module 105 btransmits data about a connected battery unit 195 b to the computingdevice 110. After the module 105 b finishes transmitting data, themodule 105 b sends a data request signal to the third battery unitmonitoring module 105 c, and the process continues for the rest of themonitoring modules 105.

Using this communication system, the computing device 110 can match datawith a battery unit according to the order in which the device 110receives data. Thus, the first set of data can be matched to the firstbattery unit 195 a, the second set of data to the second unit 195 b, andso forth. In this manner, the computing device 110 uses few ports forobtaining data and matching the data to battery units 195. In someembodiments, such a battery management system 100 may eliminate theneeds for dedicated addressing ports, addressing switches, and/orjumpers.

When the computing device 110 does not receive data from a battery unit195 for at least a predetermined period of time (e.g., 20 ms, althoughother times may be used), the computing device 110 can conclude thatdata collection for the battery pack 190 has been completed. Thecomputing device 110 can obtain another set of data by transmittinganother data request to the first battery unit monitoring module 105 a,thereby restarting the data collection process. In some embodiments, thecomputing device 110 can collect data about the battery units 195, e.g.,once per 1-2 seconds.

In some embodiments, the computing device 110 can first compare thenumber of data received with the number of monitoring modules 105. Ifthe numbers match, the computing device 110 can determine all themonitoring modules 105 are operational and continue obtaining data aboutthe battery units 195. If the numbers do not match, the computing device110 can conclude that at least one monitoring module 105 and/or batteryunit 195 is not operational. The computing device 110 can generate andoutput an error message to the display 115. Since the modules 105transmit data to the computing device 110 in sequential order, thecomputing device 110 can identify the non-operational module 105 or unit195 according to the number of data received. In this manner, thecomputing device 110 can inform a user of physical locations of faultsin the monitoring modules 105 or battery pack 190, allowing the user totroubleshoot problems.

Regarding the individual monitoring modules 105, in some embodiments, amodule 105 can measure data for a connected battery unit 195 uponreceiving a data request signal. In some embodiments, a module 105 canmeasure and store data in a buffer. Then, when the module 105 receivesthe data request signal, the module 105 may access the buffer and maytransfer the data stored therein to the computing device 110.

The monitoring module 105 can transmit the data to the computing device110 in a human readable form. The monitoring modules 105 can transmitthe data via an asynchronous serial protocol, such as protocols used forRS-232 or USB connections. The monitoring modules 105 can transmit thedata at any rate and with any number of start and/or stop bits. Forexample, a module 105 can transmit at 9600 Baud with 1 start bit and 1stop bit.

Referring now to FIG. 4, a diagram depicting connections between batteryunit monitoring modules 105 is shown and described. In some embodiments,wiring 400 (e.g., ribbon cable, 4-wire round shape harnesses) can beused to connect the monitoring modules 105 to one another. In someembodiments, for each monitoring module 105, the output data port can belocated in the center of a module's 105 interface. In some embodiments,the input data request port and the output data request port can besymmetrically located on opposite sides of the output data port. Byorienting each battery unit monitoring module 105 in an oppositedirection from adjacent modules 105, wiring 400 can connect the outputdata request port of one module 105 to the input data request port ofthe successive module 105. Due to the orientation of the ports, thewiring 400 need not be twisted or folded. Further, the wiring 400 canconnect all the output data ports to the input data port of thecomputing device 110. When a monitoring module 105 transmits data forits connected battery unit 195, the data can be sent across each portionof wiring 400 connecting the monitoring modules 105 before the dataarrives at the computing device 110.

FIG. 5 is a hybrid block and circuit diagram depicting an exemplarybattery unit monitoring module 105. The monitoring module 105 includesterminals 502 and 503, a microprocessor 505, a reverse connectionprotection system 510, a battery unit balancing system 515, a voltageregulator 520, resistors 525, 526 for sampling a battery unit's 195voltage, and a temperature monitoring device 527 (e.g., a thermistor)for sampling a battery unit's 195 temperature. The monitoring module 105also includes a receiver 540 for receiving a data request signal from acomputing device 110 or monitoring module 105, a driver 541 fortransmitting data of the connected battery unit 195 to the computingdevice 110, and a driver 542 for transmitting a data request signal toanother monitoring module 105.

A battery unit 195 connects to the monitoring module 105 at terminals502 and 503. Thus, the battery unit 195 applies its voltage to thereverse connection protection system 510. If the voltage is sufficientlyhigh, the protection system 510 conducts and applies the voltage to thevoltage regulator 520, resistors 525, 526, temperature monitoring device527, and balancer 515. If the battery unit 195 is improperly connectedto the terminals 502, 503 (e.g., with incorrect polarity), the reverseconnection protection system 510 does not conduct, thereby protectingthe module 105 from potentially damaging voltages.

When the protection system 510 conducts, the voltage regulator 520 candraw upon the battery unit's 195 voltage to supply a stable voltage(e.g., 2V) for the monitoring module 105. In particular, this voltagecan power the microprocessor 505. The microprocessor 505 can obtain thebattery unit's 195 voltage via resistors 525 and 526 and/or thetemperature via temperature monitoring device 527. In some embodiments,the microprocessor 505 can sample the values on the resistors 525, 526and temperature monitoring device 527 to obtain the voltage andtemperature. The microprocessor 505 can store the values in an internalmemory.

In some embodiments, when the receiver 540 receives a data requestsignal, the receiver 540 transmits the signal to the microprocessor 505.In response, the microprocessor 505 obtains the voltage and temperatureof the battery unit 195, either by measuring the values on the resistors525, 526 and temperature monitoring device 527 or by accessing storedvalues in an internal memory. The microprocessor 505 transmits thevalues to the driver 541, which drives the values back to the computingdevice 110 via, for example, asynchronous serial ASCII communication. Atsubstantially the same time, the microprocessor 505 can generate andoutput a data request signal to the driver 542. The driver 542 drivesthe data request signal to the next monitoring module 105 for obtainingdata about its connected battery unit 195.

Referring now to FIG. 6, a circuit diagram of an exemplary embodiment ofa battery unit monitoring module 105 is shown and described. In thisembodiment, the terminals 602, 603 correspond to the terminals 502, 503of FIG. 5. The protection system 510 can be a metal-oxide-semiconductorfield effect transistor (MOSFET) 605, such as a p-type MOSFET. Terminalsof the battery unit 195 can connect to both the source and base of theMOSFET 605. When the battery unit's 195 voltage is sufficiently high,the voltage activates the MOSFET 605. As the MOSFET 605 conducts, thebattery unit 195 applies its voltage to the voltage regulator 610. Ifthe battery unit's 195 voltage is insufficiently high, or its polarityis reversed, the MOSFET 605 does not conduct, thereby protecting themodule 105 from potentially damaging voltages. In this manner, theMOSFET 605 can operate as a low voltage drop diode.

The voltage regulator 610 can be an integrated circuit (e.g., a LP2951)which can use a transistor 611, two operational amplifiers 612, 613, andtwo resistors 614, 615 to regulate a voltage. Resistors 616, 617 candivide the output of the voltage regulator 610 to, for example, 2V. Thedivided voltage can be fed back to the error amplifier 612, and theregulator 610 can adjust the output accordingly. In this manner, thevoltage regulator 610 can output a substantially constant voltage. Thecapacitor 618 can filter the divided voltage before supplying thevoltage to a microprocessor 620. Further, a power supply can power adock generator (with capacitors 623, 624, an oscillator 625, resistor626, and buffers 627, 628) to generate a clock signal. The clock signalcan be provided to the microprocessor 620 for its operations.

The battery unit 195 can connect, via the terminals 602, 603, toresistors 629, 630 and a thermistor 631. A node between the resistors629, 630 and a node adjacent to the thermistor 631 can connect to inputports of the microprocessor 620, which in turn can connect to aninternal analog-to-digital converter (also referred to herein as A/Dconverter). One of the inputs to the internal A/D converter can samplethe voltage between the resistors 629, 630 to determine the voltage ofthe battery unit 195. Another input to the internal A/D converter cansample the temperature of the battery unit 195, expressed as a voltage,via the thermistor 631. The microprocessor 620 can store the voltage andtemperature in an internal memory. In some embodiments, themicroprocessor 620 connects to separate A/D converters that sample thevoltage and temperature.

The microprocessor 620 can receive a data request signal via thereceiver 640 (e.g., an optocoupler). In response, the microprocessor 620can obtain the voltage and temperature of the battery unit 195 andtransmit the values to the driver 641, which drives the values back tothe computing device 110. At substantially the same time, themicroprocessor 620 can generate and output a data request signal. Thedata request signal can connect to the base of a transistor 650. Whenthe signal turns on the transistor, current flows through the driver 642to output another data request signal to the next monitoring module 105.

FIG. 7 is a circuit diagram of an exemplary embodiment of an interface700 for the computing device 110. The interface 700 can be used by thecomputing device 110 for communicating with to battery unit monitoringmodules 105. The computing device 110 can apply a data request signal tothe gate of a transistor 705, such as a metal-oxide-semiconductorfield-effect transistor (MOSFET). In response, the transistor 705conducts and current flows from the voltage source 710 through theresistors 715, 716. The voltage that develops at the node between theresistors 715, 716 activates the transistor 720. As a result, currentflows from the voltage source 710 through the transistor 720 andresistor 721 to output a data request signal (e.g., a logic high signal)for the first battery unit monitoring module 105.

The circuit can receive a data signal (e.g., as 12V signal) through theTX pins on a connector. Resistors 725, 726 can divide the data signal,and the Zener diode 730 can clamp the data signal to a voltagesubstantially equal to the voltage supplied to the battery unitmonitoring module's microprocessor (e.g., 3.3V). An inverter 735, suchas a Schmitt Trigger inverter, can eliminate noise and sharpen the riseand fall times of the divided and/or clamped data signal before passingthe data signal to the microprocessor of the computing device 110.

In various embodiments, the interface 700 can be located on the sameboard as the other components of the computing device 110. In someembodiments, the communication interface can be isolated from thoseother components.

FIG. 8 is a circuit diagram of an exemplary embodiment of a balancingunit 800 of a battery unit monitoring module 105. The operation of thebalancing unit is described in U.S. application Ser. No. 12/939,889,entitled “Battery Unit Balancing System,” filed Nov. 4, 2010, thecontents of which are hereby incorporated by reference in theirentirety.

FIG. 9 is a block diagram depicting an exemplary embodiment of thecomputing device 110 of the battery management system 100. The computingdevice 110 can include a central processing unit (CPU, e.g. 8-coreprocessor) 905 and a memory 910 (e.g., electrically erasableprogrammable read-only memory, or EEPROM serial memory) that stores aprogram with executable instructions. The program can be loaded into thememory 910 from an external device connected via, for example, the businterface 965 or a USB cable. The CPU 905 can load and executeinstructions from the memory 910 to perform its operations. The programmay include configuration data, such as the predetermined number ofbattery unit monitoring modules 105 in the system 100 or the thresholdbattery unit voltage or temperature that would trigger an errorcondition. In some embodiments, the program may obtain the configurationdata from values input by a user of the system 100.

The computing device 110 can use an analog-to-digital (A/D) converter915 to measure the voltage of the battery pack 190. The A/D converter915 can sample the voltage to obtain a value. The computing device 110can use an analog-to-digital (A/D) converter 916 to measure the currentof the battery pack 190. In some embodiments, the A/D converter 916 isconnected to a shunt, which in turn is connected to a terminal of thebattery pack 190 and a terminal of the external load 198. The shunt canbe a resistor that develops a voltage drop proportional to the batterypack's 190 current (e.g., 0.0001 Ohms developing a voltage drop of 0.1mV/A). An amplifier 917 can amplify the value of the current before theA/D converter 916 samples the current. The A/D converters 915, 916 candirect the battery pack voltage and current to an isolation barrier 920controlled by a signal from a connection fault detector 925. In someembodiments, the A/D converters 915, 916 are on the same board as theCPU 905, isolated, and/or both.

The connection fault detector 925 can signal the presence of aconnection between a battery unit 195 and a zero-voltage referencelevel. For example, the zero-voltage reference level can be the batterypack's 190 enclosure or chassis, and the connection between a batteryunit 195 and the chassis would represent a hazard to service personnel.When one or more battery units 195 within the battery pack 190 contactsa point at the zero-voltage reference level, the contact can causecurrent to flow from the battery unit 195. The connection fault detector925 detects the connection and outputs a signal to the CPU 905 whichwill display a warning indicating this connection on the display device115.

The CPU 905 can connect to the battery unit monitoring modules 105 toobtain data about the individual battery units 195, as described inreference to FIGS. 3-5. The CPU 905 can process data about theindividual battery units 195 and/or battery pack 190 to create acomposite video signal. A digital-to-analog (D/A) converter 930 (e.g., a3-bit converter) can produce the composite video signal from digital toanalog format so the signal can be displayed on a display 115.

If the CPU 905 detects an error condition, the CPU 905 can transmit anerror signal to an alarm output system 940. The system 940 can be usedto control a component and/or device that responds to the error signal(e.g., a charger that stops charging the battery pack 190, or a motorcontroller of an electric vehicle that stops discharging the battery).

The computing device 110 can include power supplies 960 (not shown onFIG. 9). The power supplies 960 supply voltages to components of thebattery management system 100. In some embodiments, a power supply 960can include an internal voltage regulator to provide a constant voltage.The power supplies 960 can be isolated from the other components of thecomputing device 110 to prevent damage to the device 110.

The computing device 110 can include an interface 965, such as acontroller area network (CAN) interface. The interface can includeports, such as parallel port pins. The computing device 110 can connectto external devices via an interface (not shown). For example, thedevice 110 can connect to another computing device to receive a programto be stored in the memory 910.

The computing device 110 can include a port 970 for receiving a pageselect signal. A page can correspond to a format for displaying dataabout a battery unit 195 within the battery pack 190. For example, onepage can display the data for the entire pack 190. Another page candisplay the voltages and temperatures of eight, twenty, or any othernumber of battery units 195. Successive pages can display the sameinformation for adjacent sets of battery units 195. The computing device110 can receive the page select signal from a switch mounted in adashboard in an electric vehicle, for example (not shown). In response,the computing device 110 can output the selected page containing batterypack data to the display 115.

FIG. 10 is a block diagram depicting an exemplary embodiment of thealarm output system 940 of the computing device 110. The alarm outputsystem 940 receives an error signal from the computing device 110. Thealarm output system 940 outputs a binary signal according to the errorsignal. If the error signal corresponds to an off signal, the system 940allows current to flow to a ground reference, thereby outputting a logiclow signal (e.g., 0V). If the error signal corresponds to an on signal,the system 940 allows current to flow from a voltage source, such as12V. In some embodiments, the system 940 does not allow current to flowuntil the error signal lasts at least 30 seconds. In this manner, thesystem 940 turns on or off external devices according to the presence ofan error.

FIG. 11 is a circuit diagram depicting an exemplary embodiment of thealarm output system 940 of the computing device 110. The alarm outputsystem 940 includes a voltage source 1101, two resistors 1103, 1104,four transistors (e.g., metal-oxide-semiconductor field-effecttransistors or MOSFETs) 1105, 11068, 1107, 1108 configured to form an Hbridge, and two transistors 1120, 1121 that operate the alarm outputsystem 940. Transistors 1105, 1108 can be of opposite polarity fromtransistors 1106, 1107. The alarm output system 940 can apply one ormore received error signals to the transistors 1120, 1121 and output oneor more command signals corresponding to the error signals at terminals1130, 1131.

In operation, an error signal can be applied to transistor 1120 and/ortransistor 1121. If the computing device 110 detects a low voltagecondition, the device 110 can apply an error signal to transistor 1120.As transistor 1120 conducts, the voltage applied to the gates oftransistors 1107, 1108 by the voltage source 1101 drops. The voltagedifferential between the source and gate of transistor 1107 decreases toturn the transistor 1107 off. The voltage differential between thesource and gate of transistor 1108 increases to turn the transistor 1108on. As transistor 1108 conducts, current flows from the voltage source1101 through the transistor 1108 to the output terminal 1130. Thevoltage that develops on the output terminal 1130 can be used to shutoff a motor controller, by way of example.

If the computing device 110 detects a high voltage condition, a highcurrent condition, or a high temperature condition, the device 110 canapply an error signal to transistor 1121. As transistor 1121 conducts,the voltage applied to the gates of transistors 1105, 1106 by thevoltage source 1101 drops. The voltage differential between the sourceand gate of transistor 1106 decreases to turn the transistor 1107 off.The voltage differential between the source and gate of transistor 1108increases to turn the transistor 1105 on. As transistor 1105 conducts,current flows from the voltage source 1101 through the transistor 1105to the output terminal 1131. The voltage that develops on the outputterminal 1130 can be used to shut off a battery charger or turn on afan, by way of example.

FIG. 12 is a circuit diagram depicting an exemplary embodiment of theconnection fault detection system of the computing device. Theconnection fault detection system includes an optocoupler 1205 with alight emitting diode 1210 and a transistor 1215, such as aphototransistor. One terminal of the light emitting diode 1210 connectsto ground (also referred to herein as “a node at a ground zero referencelevel”), such as a chassis of an electric vehicle. The other terminal ofthe light emitting diode 1210 connects to a current sink 1220. Oneterminal of the transistor 1215 connects to a voltage source 1225. Theother terminal connects to a node corresponding to the output 1228 ofthe optocoupler 1205 (also referred to herein as the “output node”).This node connects to a resistor 1230 that also connects to a groundzero reference level, which can be electrically isolated from thebattery pack 190. The current sink 1220 connects to the negativeterminal of a voltage source 1235. The positive terminal of the voltagesource 1235 connects to the negative terminal of at least one batteryunit 195 of the battery pack 190.

In operation, when none of the terminals of the battery units 195connect to ground, current does not flow through the light emittingdiode 1210 of the optocoupler 1205. The light emitting diode 1210 doesnot activate the transistor 1215, and the transistor 1215 does notconduct. Because the node 1228 corresponding to the optocoupler's 1205output is disconnected from the voltage source 1225, any charge at thenode drains through the resistor 1230 to ground. In this manner, theoptocoupler 1205 outputs a logic low signal, such as 0V, indicating thata connection fault has not been detected.

When a positive terminal of a battery unit 195 does connect to azero-voltage reference level, current flows through the light emittingdiode 1210 to the current sink 1220. The current activates thetransistor 1215 so the transistor 1215 conducts. Current flows from thevoltage source 1225, building charge at the output node 1228. Thus, theoptocoupler 1205 outputs a logic high signal indicating that aconnection fault has been detected. The logic high signal can be appliedto CPU 905, which can output a message to the display device warning anoperator of the battery unit management system of a potentiallyhazardous connection fault.

The voltage sources 1225, 1235 can have any voltage. For example,voltage source 1225 can provide 3.3V. Voltage source 1235 can provide5.0V. The current sink 1220 can limit the current flowing through itselfand the light emitting diode 1210 to any current, such as a minimum safelevel of current. For example, the current sink 1220 can limit thecurrent to 2 mA. The current sink 1220 can operate over a range ofvoltages of the battery pack 190, such as the voltages between thebattery pack's 190 positive and negative terminals. In some embodiments,this range can be from about 5V to about 500V. In some embodiments, thecurrent sink 1220 can operate at voltages that exceed the voltage at thepositive terminal of the battery pack 190.

FIG. 13 is another circuit diagram depicting an exemplary embodiment ofthe connection fault detection system of the computing device. Thisembodiment includes all the components described in reference to FIG.12. In addition, in this embodiment, the current sink 1220 includes avoltage source 1305, a first resistor 1310, a first transistor 1315, asecond transistor 1320, and a second resistor 1325. The voltage source1305 connects to one terminal of the first resistor 1310. The otherterminal of the first resistor 1310 connects to the gate of the firsttransistor 1315 and the emitter of the second transistor 1320. Thesource of the first transistor 1315 connects to the optocoupler 1205.The drain of the first transistor 1315 connects to the base of thesecond transistor 1320 and one terminal of the second resistor 1325. Theother terminal of the second resistor 1325 connects to the collector ofthe second transistor 1315 and the negative terminal of the voltagesource 1235.

In operation, current flows from the voltage source 1305 through thefirst resistor 1310 to activate the first transistor 1315 such that thefirst transistor 1315 conducts. When a terminal of a battery unit 195connects to ground, current flows through the optocoupler 1205, thefirst transistor 1315, and the second resistor 1325. The voltage thatdevelops across the second resistor 1325 activates the second transistor1320. As the second transistor conducts 1320, current is diverted fromthe gate of the first transistor 1315. The transistors 1315, 1320 andresistors 1310, 1325 reach equilibrium such that a constant currentflows through the first transistor 1315.

The transistors 1315 can be any type of transistor, such as ametal-oxide-semiconductor field-effect transistor (MOSFET), an insulatedgate bipolar transistor (IGBT), or a NPN transistor. In someembodiments, a 2N3904-type transistor is used for the second transistor1320.

FIG. 14 is a circuit diagram depicting an exemplary embodiment of thepack voltage and pack current input systems of the computing device. Thebattery pack 190 can connect to the systems at terminals 1401, 1402.Resistors 1405, 1406, 1407, 1408, 1409, 1410 can divide the battery pack190 voltage from 500V to 2V, by way of example. A capacitor 1411 canfilter the divided voltage, and an A/D converter 1415 can sample thevoltage. The A/D converter 1415 can transmit the voltage to a processorof the computing device 110, such as CPU 905. Optocouplers 1420, 1421,1422 can create an isolated communication interface between the A/Dconverter 1415 and the processor.

The voltage drop across a shunt can be input at terminal 1430. Theoperational amplifier 1435, resistors 1436, 1437, and capacitors 1438,1439, 1440 can form an amplifier to amplify the voltage drop. Becausethe amplifier has a fixed gain, such as 80, the amplified voltage mayexceed the capacity of the A/D converter 1445 that samples the voltage.Thus, resistors 1447, 1448 can form a voltage divider that divides theamplified voltage to a level the A/D converter 1445 can process. The A/Dconverter 1445 can sample the voltage and transmit the voltage to theprocessor, which can calculate the battery pack 190 current based on thevalue of the shunt. The A/D converter 1445 can use the samecommunication interface as the A/D converter 1415 to transmit itssampled voltage.

FIG. 15 is a circuit diagram depicting an exemplary embodiment 1500 ofthe central processing unit 905 of the computing device 110. Resistors1501-1519, capacitors 1520-1527, Zener diodes 1530-1532, and inverters1535-1537 condition the inputs and outputs for the central processingunit 1550.

FIG. 16 is a circuit diagram 1600 depicting an exemplary embodiment of apower supply that can be used with the battery management system 100.The power supply 1600 can be a step down switching voltage regulator.The components 1601-1616 can operate to produce a voltage, such as 5V or12V. In particular, component 1612 can be a linear voltage regulatorthat accepts a voltage produced by the other components of the systemand outputs a substantially constant 3.3V.

FIG. 17 is a circuit diagram 1700 depicting an exemplary embodiment ofanother power supply that can be used with the battery management system100. The power supply 1700 can be an isolated power supply. Components1701-1708 can operate as an oscillator that produces 40 KHz. Thetransformer with windings 1709-1711 can transfer energy produced by theoscillator to components 1712-1721, which can operate as positive andnegative half-wave rectifiers and a shunt regulator. The rectifiers andshunt regulator can operate to produce a substantially constant outputvoltage.

FIG. 18 is a circuit diagram depicting an exemplary embodiment of acontroller area network (CAN) interface used with the battery managementsystem 100. The interface can be used to connect a CPU 905 of acomputing device 110 with an external device via a CAN bus. A connector1801 can attach to a component of the computing device 110, such as theCPU board. The other connector 1880 can attach to a CAN bus thatconnects to an external device. The computing device 110 and externaldevice can communicate over the interface using a standard bus protocolsuch as a serial peripheral interface (SPI) protocol. In someembodiments, the devices can use handshaking signals, such as receiverbuffer full and interrupt.

The interface chip 1805 can operate in a non-isolated mode or anisolated mode. In the non-isolated mode, the interface chip 1805communicates with the bus buffer 1810 with data received, for example,from an external CAN-enabled device. In some embodiments, the bus buffer1810 can receive data from the bus ports 1880. The interface chip 1805can send a transmit signal to the buffer 1810 so the buffer 1810 outputsits data to the bus ports 1880. The interface chip 1805 can send areceive signal so the buffer 1810 outputs its data obtained from the busports to the interface chip 1805.

In the isolated mode, an isolator 1815 isolates the interface chip's1805 transmit and receive signals from a buffer 1820. The isolator 1815can be a magnetic isolator. An isolated power supply 1825 can use avoltage from a voltage regulator 1828 to provide power for the isolator1815 and buffer 1820. In some embodiments, the voltage regulator 1828receives a 12V signal and outputs a 5V signal.

In view of the structure, functions and apparatus of the systemdescribed herein, the present disclosure provides an efficient andintelligent battery management system. Having described certainembodiments of the battery management system, it will now becomeapparent to one of skill in the art that other embodiments incorporatingthe concepts of the disclosure may be used. Therefore, the inventionshould not be limited to certain embodiments, but should encompass thespirit and scope of the claims.

As shown in FIG. 19, a lithium battery has a non-linear dischargeprofile. The discharge rate from approximately 5% to 80% of full chargeis substantially linear but has a very small slope. Therefore, it isdifficult to estimate the state of charge of a battery, or battery unitby measuring the voltage. Small variations in voltage may result inerroneous estimates of the state of charge. As described herein, a powercontrol system may calculate the time remaining before a battery packshould be shut down when being used as the output power supply. Thepower control system and specifically the computing device may initiatebattery shut down if a calculated value of 80% discharged or more isreached.

As shown in FIG. 20, an exemplary lithium battery power supply system 10comprises a battery pack 12, and a power control system 14. The batterypack 12 has a first battery unit 20 and a second battery unit 20′. Abattery data input provides data about the status of the battery unitand batteries configured therein to the computing device 52 through thebattery data input 62. A computing device may request data from batterymonitoring modules (not shown), through the data request output 64. Thebattery pack is coupled to the power control system 14 by a batterypower input 40. An AC power input 42 is connected to an AC power line orcable. In an exemplary embodiment, the power control system utilizes theAC power for output power unless there is an interruption or disturbancein the incoming AC power. A data transmission system 18 is configured tosend pertinent data related to the battery management system to anexternal location, such as a monitoring station. A powered device 54 isconnected to the power control system at the power output connector 50.The battery management system 100 controls the charging and dischargingof batteries and balances the battery system to prevent large variationsbetween individual battery voltages within a battery pack. A dischargecircuit may be used to reduce the voltage of a battery when has avoltage higher than the other batteries in the battery pack. Thisdischarge circuit may be used as a battery heating circuit, wherein aresistor or transistor that heats with current flow acts as the heaterfor the battery.

As shown in FIG. 21, an exemplary power control system 14 comprises aplurality of inputs, outputs and indicators. In an exemplary embodiment,a power control system is configured in a single enclosure 15, therebymaking installation of the battery management system quick and easy. Abattery power input 40 is configured to connect to a battery pack toreceive power from said battery pack. A battery on/off switch 41 may beused to temporarily disable battery power in the event that the systemrequires maintenance or repair. An AC power switch 44 is also shown. Apower output connector 50 is configured for providing power to anelectronic device and may be any suitable type of plug. An AC powerinput 42 is configured to couple to an AC power line or cable and mayalso comprise any suitable type of plug. An AC power switch isconfigured to enable or disable AC power input. A battery data input 62is configured to couple to a battery monitoring module to receive datainput regarding the battery pack, unit or individual batteries. Asdescribed herein a battery data input may be configured to receive adata transmission cable and in some embodiments, comprises a wirelesssignal receiver. A remote data output connector 80 is configured tocouple with a cable or line, such as a phone-line, DSL line, fiber opticline and the like. Again, a remote data output connector may be awireless signal transmitter that is configured to send data outputwirelessly. A number of indicators, such as lights, are also shown, acomputing device indicator 85, a data reception indicator 84, a datatransmit indicator 83 and an AC input indicator 82. These indicators mayindicate that a particular function is current active.

As shown in FIG. 22, an exemplary battery pack 12 comprises two batteryunits 20 and 20′, each having four individual lithium batteries 21. Thebatteries are all connected in series by jumpers 27. A jumper 27′connects the first battery unit 20 with the second battery unit 20′.Battery monitoring modules 30 are configured between the positive 28 andnegative 29 terminals of the batteries. A battery monitoring module maycomprise a voltage sensor 34 and/or a temperature sensor 36. A circuit87 on a module 30 may be configured to determine the voltage state of abattery. Module connectors 32 connect battery monitoring modules in adaisy-chain configuration. Module connector 32′ couples a batterymonitoring module from the first battery unit to a battery monitoringmodule on the second battery unit. A battery power cable 26 isconfigured to provide power to the power control system. A batterymodule cable 61 is configured to couple with a battery data input, asshown in FIG. 22.

As shown in FIG. 23, an exemplary battery management system 100comprises a battery pack 12 and a power control system 14. In thisexemplary embodiment, only a battery power cable physically couples thebattery pack to the power control system. Data from the batterymonitoring modules 30 is wirelessly transmitted to the power controlsystem. A wireless transmitter 66 and wireless receiver 68 are coupledon the battery pack 10 and transmit battery status information to thecontrol system. Likewise, the control system comprises a wirelesstransmitter 66′ and wireless receiver 68′ for requesting battery statusinformation and receiving battery status information respectively. Apowered device 54 is plugged into the power output connector 50. An ACpower line 43 is coupled with the power control system.

As shown in FIG. 24, an exemplary automatic control system 1800comprises an automatic control circuit 850 circuit that enablesautomatic control of the charging and discharging of a battery withoutinterruption of disconnects or shut-downs due to irrelevant alarms. Theautomatic control system is used in conjunction with a batterymanagement system 60, as described in any of the embodiments herein. Thebattery management system provides the automatic control system with anunder-voltage output 864 signal when the battery is below a lower chargethreshold value and is ready for charging, an over-voltage output 862signal when the battery is above an upper charge threshold and is readyfor discharging. A current flow output, 866 such as a MODBUS, orequivalent, provides a measure of the current to a load 904 or from apower source 903 for charging, or charging power source. Amicroprocessor 801 receives these inputs and opens or closes the relaycontactor based on these outputs from the battery management system 60,and one of two optocouplers, a discharge optocoupler 806 and chargeoptocoupler 807. The optocouplers are arranged in anti-parallel, so thata sufficient voltage, either positive or negative polarity, from thedifference amplifier, will turn on one of the two optocouplers. Asufficient absolute value of voltage to turn on an optocoupler may be1.0V or more, 1.5V or more, 1.75V of more, 2.0V or more and any rangebetween and including the values provided. The voltage value produce bythe difference amplifier is dependent on the resistance value of theparallel resistor and the difference in potential between the state ofcharge of the battery and the load or charging power source.

Isolating the battery 802 from the load 904 or charging power source 903for charging is done by a relay 883 having a single relay contactor 808under control of the microprocessor 801. The relay comprises the singlerelay contactor 808 and a transistor 882. A parallel resistor 810 isconfigured in parallel with the relay contactor from an input side 892to an output side 894. The parallel resistor provides a voltagepotential value to the difference amplifier. The relay 883 has atransistor 882 whose operating voltage is that of the battery. The relaycontactor is sized to meet the requirements of the load and the charger.Assuming the system is at rest, the relay contactor 808 of the relay isopen. The parallel resistor 810 is configured across the relay contactorand provides a voltage to the load 904 or charging power source 903 suchas a charger. If these are inactive, the voltage on the output side 894of the relay contactor 808 and the parallel resistor 810 will be thesame as the input, the battery voltage. If a load 904 is connected, thevoltage on the output side 894 of the relay contactor will go down. Thisdifference of the relay contactor 808 or parallel resistor from theinput side 892 to the output side 894 or input and out voltages will besensed by difference amplifier 805 and indicated by dischargeoptocoupler 806 to microprocessor 801. As long as the battery is notdischarged as indicated by the under-voltage output 864 on the batterymanagement system 60, the microprocessor will activate the relaycontactor via transistor 809. As soon as the relay contactor 808 isclosed, the voltage differential between the output side and input sidewill become zero, and the output of the discharge optocoupler 806 willturn off. In order for the microprocessor to make the decision to keepthe relay contactor closed, it must read a current flowing in the shunt803 via the current flow output (MODBUS) 866, or other similarcommunications means, from the battery management system 60. Should thecurrent stop flowing through the shunt 803, the microprocessor will readthis from the port on battery management system 60 and open the relaycontactor 808 thereby isolating the battery 802 once more.

Battery charging is done in a similar fashion as discharging as outlinedabove. Assuming the system is at rest, the relay contactor 808 is open.Parallel resistor 810, which is configured in parallel with the relaycontactor, provides a voltage to the difference amplifier 805 so thatthe charging power source 903 will start its' charging cycle. If thecharging power source 903 begins charging, the output side 894 voltagewill rise above the battery 802 voltage. This difference of the relaycontactor 808 input voltage and output voltage, or voltage drop acrossthe relay contactor from the output side 894 to the input side 892, willbe sensed by difference amplifier 805 and indicated by chargeoptocoupler 807 to microprocessor 801. As long as the battery is notcharged as indicated by the over voltage output on the batterymanagement system 60, the microprocessor 801 will activate the relaycontactor 808 to close via transistor 809. As soon as the relaycontactor 808 is closed, the voltage differential between the output andinput will become zero, and the output of charge optocoupler 807 willturn off. In order for the microprocessor 801 to make the decision tokeep the relay contactors closed, it must read a current flowing in theshunt via the MODBUS, or other similar communications means, from thebattery management system 60. Should the current stop flowing throughthe shunt 803, the microprocessor will read this from the port onbattery management system 60 and deactivate open the relay contactor 808thereby isolating the battery 802 once more.

The battery management system 60 has two state of charge status outputs.The over voltage output 862 indicates that the battery is not chargedwhen high, and when low the microprocessor 801 will not allow thecharging power source 903 to be connected to the battery 802. Theunder-voltage output 864 indicates that the battery is not dischargedwhen high, and when low the microprocessor will not allow the load 904to be connected to the battery. In this way, when the battery has astate of charge below a lower threshold value, the battery can becharged and any under-voltage signals from the battery management systemare ignored and when the battery has a state of charge above an upperthreshold value, any overvoltage outputs signals from the batterymanagement system are ignored and the battery can be discharged. Anerror, such as a failure of the battery management system's ability toread individual cell voltages, will cause both outputs of the batterymanagement system 60 to go low thereby signaling the microprocessor 801to not allow any charging or discharging the battery 802 by openingrelay contactor 808. The automatic battery control system andparticularly the battery management system may be powered by an isolatedpower supply 804 that is fed by a 5V power supply that runs the system.

Referring now to FIG. 25, in an exemplary embodiment, a battery unitwill be discharged as long as it is above a threshold discharge value872, which is offset above the lower threshold limit 870. The thresholddischarge value may be set some offset voltage above the lower thresholdlimit to prevent cycling the battery between charge and discharge modestoo frequently. In an exemplary embodiment, a battery unit will becharged as long it is below a charge threshold limit 876, which isoffset below the upper threshold limit 878. It is to be understoodhowever that the threshold discharge value and the lower threshold limitmay be substantially the same value or the same value, and the thresholdcharge limit and upper threshold limit may be substantially the samevalue or the same value. As shown, the system is designed to prevent thebattery state of charge from entering into an overcharge state of chargeor undercharge state of charge, which may damage the battery unit.

As shown in FIG. 26, a battery management system 60 provides an overvoltage output signal to a microprocessor 801 and when dischargeoptocoupler 806 is providing a discharge-mode signal to themicroprocessor that the system is in a discharge mode, the over voltageoutput signal is ignored and the battery continues to discharge.However, when the discharge optocoupler is not providing thedischarge-mode signal, then the relay is opened to isolate the batteryfrom the load and/or the charger.

As shown in FIG. 27, a battery management system 60 provides an undervoltage output signal to a microprocessor 801 and when the chargeoptocoupler 807 is providing a charge-mode signal to the microprocessorthat the system is in a charge mode, the under voltage output signal isignored and the battery continues to charge. However, when the chargeoptocoupler is not providing the charge-mode signal, then the relay isopened to isolate the battery from the load and the charger.

As shown in FIG. 28, an exemplary automatic rechargeable battery controlmodule 1900 has a single power connector 1910. An exemplary automaticcontrol system 1800, as described herein having an automatic batterycontrol circuit 1930, is configured within the housing 1902 along withone or more rechargeable batteries 1940. The exemplary automaticrechargeable battery control module 1900 also has an on/off switch 1920,making installation and operation of the automatic rechargeable batterycontrol module 1900 very easy. A battery controller 1924 and an inverter1922 may also be configured in the housing 1902.

As shown in FIG. 29, an exemplary automatic rechargeable battery controlmodule 1900 comprises a plurality of individual rechargeable batteries1940 to produce a battery pack 1940. As shown, sixteen rechargeablebatteries are configured to produce a 48-volt output when therechargeable batteries are lithium ion batteries having a voltage of3.2V. The exemplary automatic rechargeable battery control module 1900comprises an inverter 1922 and battery controller 1924. The exemplaryautomatic rechargeable battery control module 1900 comprises anautomatic control system 1800, as described herein having an automaticbattery control circuit 1930.

As shown in FIG. 30, an exemplary automatic rechargeable battery controlmodule 1900 is connected to a maximum power point tracker, MPPT 1970, bya single power connection line 1905 which may be a DC power line. TheMPPT couples the automatic rechargeable battery control module 1900 withthe load 1960, a dwelling 1962, and a power source 1950, a photovoltaiccell 1952. Note that the MPPT may also couple a grid power supply by agrid power line 1963 with the automatic rechargeable battery controlmodule 1900. An exemplary MPPT has an alternative power connector 1975,a load connector 1976, and a battery module connector 1971. Note thatonly one power connection line 1905 is connected with the powerconnector 1910 of the automatic rechargeable battery control module1900. A load from the automatic rechargeable battery control module 1900is provided through this single power connection line and power isreceived by the automatic rechargeable battery control module 1900through this same line. The exemplary automatic control system 1800 ofthe automatic rechargeable battery control module 1900 automaticallyswitches the battery module from a power discharge mode to a chargemode, thereby eliminating the need for separate power lines and powerline connectors, one for charging and one for power supply from abattery module. Note that the MPPT may comprise a power converter 1972,such as an DC/AC converter to provide power to the load 1960, or loadinterface 1964, in a proper form. A alternative power line 1955 connectsthe alternative power source 1950 with the MPPT 1970 at the alterativepower connector 1975. A load power line 1965 connects the load 1960 withthe MPPT 1970. Note that a grid power line 1963 may also be coupled withthe load 1960 at the load interface 1964 and the battery pack of theautomatic rechargeable battery control module 1900 may be charged bygrid power when the alternative power source 1950 is not producing powerand the battery pack requires charging.

As shown in FIG. 31, an exemplary automatic rechargeable battery controlmodule 1900 is connected to a power controller 1992 that may comprise aninverter 1993 to produce an AC power supply for use by a load 1960, suchas a home or dwelling 1962. An alternative power supply 1950 is alsoconnected to a power controller 1982, which may be a solar powercontroller that regulates power from the solar panels. Power from aphotovoltaic cell 1952 may have varying voltages depending on theintensity of the light and therefore a power controller 1982 for solarpower may regulate the voltage as required for a load and may comprisean inverted to produce AC power. A grid power line 1963 is also coupledwith a power controller 1992 which may be electrically coupled with apower controller or inverter the connects with the alternative powersource 1950 or the automatic rechargeable battery control module. Apower controller may control the flow of power to the load from one ofthe sources including the grid power, the alternative power source orthe automatic rechargeable battery control module. In an exemplaryembodiment, a power controller may use power from the alternative powersource and/or grid during the day when power rates are low and then usepower from the automatic rechargeable battery control module during theevening, when power rates are higher. Likewise, a power controller maycharge the battery pack of the automatic rechargeable battery controlmodule with grid power and/or power from the alternative power sourceduring the day when power rates are low and then use this stored powerduring the evening when rates are higher.

As shown in FIG. 32, a plurality of exemplary automatic rechargeablebattery control modules 1900 to 1900″ are stacked and electricallycoupled in parallel and have a single connector 1910. A single powerconnection line 1905 couples the module stack 1901 to a MPPT 1970. Thismodular arrangement enables a user to add more battery storage capacitydepending on the requirement of the application. A small dwelling orapartment may only require 10 kW hours a day and single automaticrechargeable battery control module 900 may be sufficient. However, alarger single family home with more residents, may require threeautomatic rechargeable battery control modules, 1900 to 1900″, as shownto provide up to about 30 kW hours per day.

FIG. 33 shows a diagram for an exemplary automatic rechargeable batterycontrol module 1900 comprising a battery pack 1942 having two parallelsets of four batteries 1940 each, and an automatic control system 1800having an automatic battery control circuit 1930 that automaticallyswitches from a charging mode to a discharging mode and does not requireany manual resetting to switch from one mode to the other. In addition,the automatic control system also monitors the battery or battery packand the state of charge to prevent overcharging or dropping below alower threshold state of charge. Sense boards 1946 are coupled with eachof the batteries 1940 and communicate a state of charge of the batterywith the automatic control system. A low voltage disconnect circuit 1958disconnects the battery pack 1942 from a load in the event the batterypack drops below a discharge threshold value and turns off the automaticrechargeable battery control module if the state of charge of thebattery pack drops below critical threshold value. The automatic controlsystem 1800, including the microprocessor 801, sensors 1936 and senseboards 1946 are powered by power from the battery pack, typically at12V. This is a parasitic load on the battery pack and in the event thatthere is no power to charge the battery pack for an extended period oftime, the battery pack may drop below a critical threshold state ofcharge and the automatic rechargeable battery control module may be turnoff by the low voltage disconnect circuit 1958 to prevent damage to thebatteries. The automatic control system 1800 comprises a relay contactor808 having a parallel resistor 810 that enables determination of therequirement of charging or discharging modes, as described herein and asshown in FIG. 24. In addition, temperature sensors 1936 are coupled withthe batteries 1940 to monitor the temperature of the batteries. In theevent that one of the batteries exceeds and upper threshold limit, thebattery or battery pack may be disconnected from the load and/or powersupply. The automatic rechargeable battery control module 1900 has asingle power connector 910 to provide a discharge power from the batterypack to a load and to receive power to the battery pack from a powersource to charge the battery pack. The automatic rechargeable batterycontrol module 1900 has an on/off switch 1920 which may be any suitableuser interface to turn the module on and off. The automatic rechargeablebattery control module 1900 has an automatic battery control circuit1930, as generally shown in FIG. 24. The shunt 1944 is shown configuredbetween the battery pack 1942 and the automatic control system 1800.

It will be apparent to those skilled in the art that variousmodifications, combinations and variations can be made in the presentinvention without departing from the spirit or scope of the invention.Specific embodiments, features and elements described herein may bemodified, and/or combined in any suitable manner. Thus, it is intendedthat the present invention cover the modifications, combinations andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. An automatic rechargeable battery control modulecomprising: a) a module housing comprising: i) a plurality ofrechargeable batteries; b) a single power connector that receiveselectrical power to recharge said plurality of rechargeable batteriesand also delivers power from the plurality of rechargeable batteries; c)an automatic battery control system comprising: i) a battery unit; ii) amicroprocessor; iii) a battery management system that measures a stateof charge of said battery unit and comprises: an over-voltage outputthat provides an over-voltage signal to said microprocessor when thebattery unit has a measured state of charge greater than an upperthreshold limit; an under-voltage output that provides an under-voltagesignal to said microprocessor when the battery unit has a measured stateof charge less than a lower threshold limit; and a current flow outputthat provides a current signal of current flow direction into or out ofsaid battery to said microprocessor; iv) an automatic battery controlcircuit coupled to the battery management system, the microprocessor andthe battery unit and comprising: a relay comprising: a single relaycontactor extending from an input side to an output side; and atransistor; a parallel resistor configured in parallel with the relaycontactor from said input side to said output side; a dischargeoptocoupler coupled between the automatic battery control circuit andthe microprocessor; a charge optocoupler coupled between the automaticbattery control circuit and the microprocessor; a difference amplifierthat senses a relay potential that is a voltage potential across theparallel resistor and communicates with the discharge optocoupler andcharge optocoupler; wherein the discharge optocoupler sends a signal tothe microprocessor when the relay potential from the inlet to outletside is positive; wherein the charge optocoupler sends a signal to themicroprocessor when the relay potential from the inlet to outlet side isnegative; wherein with the relay contactor open, a reduction in anoutput side voltage of the output side is indicated by the dischargeoptocoupler to the microprocessor, and when the battery is above athreshold discharge limit, the relay contactor is closed by saidtransistor and the battery unit is connected to a load and place theautomatic battery control system in a discharge mode; and wherein withthe relay contactor open, an increase in the output side voltage of theoutput side is indicated by the charge optocoupler to themicroprocessor, and when the battery is below a threshold charge limit,the relay contactor is closed by said transistor to connect the batteryunit to a charging power source to place the automatic battery controlsystem in a charge mode.
 2. The automatic rechargeable battery controlmodule of claim 1, wherein when in said discharge mode and when nounder-voltage signal is received by the microprocessor from theunder-voltage output the relay contactor remains closed and the relaypotential will be substantially zero, and the output of the dischargeoptocoupler will turn off preventing said over-voltage signal fromcausing the relay to be opened; wherein the relay will remain closed aslong as the current flow output provides a current signal of a currentflowing to the load; and wherein when said current signal of a currentflowing to the load from the battery unit stops, the microprocessor willopen the relay contactor thereby isolating the battery unit from theload.
 3. The automatic rechargeable battery control module of claim 2,wherein the microprocessor opens the relay contactor when the batteryunit drops below the lower threshold limit.
 4. The automaticrechargeable battery control module of claim 1, wherein when in saidcharge mode and when no over-voltage signal is received by themicroprocessor from the over-voltage output, the relay contactor remainsclosed and the relay potential will be substantially zero, and theoutput of charge optocoupler will turn off preventing any under-voltagesignals from causing the relay to be opened; and wherein the relay willremain closed as long as the current flow output provides a currentsignal of a current flowing to the battery unit; and wherein when saidcurrent signal of a current flowing to the battery unit stops, themicroprocessor will open the relay contactor thereby isolating thebattery unit from the charging power source.
 5. The automaticrechargeable battery control module of claim 4, wherein themicroprocessor opens the relay contactor when the battery is above theupper threshold limit.
 6. The automatic rechargeable battery controlmodule of claim 1, wherein the upper threshold limit is the same as thethreshold discharge limit.
 7. The automatic rechargeable battery controlmodule of claim 1, wherein the lower threshold limit is the same as thethreshold charge limit.
 8. The automatic rechargeable battery controlmodule of claim 1, wherein the upper threshold limit is higher thanthreshold discharge limit.
 9. The automatic rechargeable battery controlmodule of claim 1, wherein the lower threshold limit is lower thanthreshold charge limit.
 10. The automatic rechargeable battery controlmodule of claim 1, wherein the parallel resistor has a resistance valueof 10,000 ohms or more.
 11. The automatic rechargeable battery controlmodule of claim 1, further comprising a battery unit monitoring modulethat is electrically connected to the positive terminal and the negativeterminal of the battery and measures a state of charge of the battery.12. The automatic rechargeable battery control module of claim 11,wherein the battery unit monitoring module comprises: a) an input datarequest port connected to an output data request port of a computingdevice of a battery management system; and b) an output data requestport; c) an output data port connected to the input data port of thecomputing device.
 13. The automatic rechargeable battery control moduleof claim 1, further comprising a battery management system comprising:a) a computing device comprising: i) an output data request port; andii) an input data port b) a first battery unit monitoring coupled with afirst battery unit and comprising: i) an input data request portconnected to the output data request port or the computing device; andii) an output data request port; c) an output data port connected to theinput data port of the computing device; and d) a second battery unitmonitoring module coupled with a second battery unit and comprising: i)a single input data request port connected only to the output datarequest port of the first battery unit monitoring module, thereindefining a module connection between said first battery unit monitoringmodule and said second battery unit monitoring module; ii) an outputdata port connected to the input data port of the computing device;wherein the first battery unit monitoring is a master to said secondbattery unit monitoring module and the second battery unit monitoringmodule is a slave to the first battery unit monitoring module; whereinthe first battery unit monitoring module responds to a data requestsignal from the output data request port of the computing device bytransmitting data of the first battery unit to the input data port ofthe computing device and subsequently transmits a data request to thesecond battery unit monitoring module through said module connection;and wherein the second battery unit monitoring module responds to thedata request from the output data request port the first battery unitmonitoring module by transmitting data of the second battery unit to theinput data port of the computing device; wherein the computing devicereceives data from the first and second battery unit monitoring modulessequentially after sending a single data request signal to only thefirst battery unit monitoring module; and wherein the computing devicereceives data from the second battery unit monitoring moduleautomatically after receiving data from the first battery unitmonitoring module.
 14. An automatic rechargeable battery control modulecomprising: a) a module housing; b) a battery unit; c) a microprocessor;d) a battery management system that measures a state of charge of saidbattery unit and comprises: i) an over-voltage output that provides anover-voltage signal to said microprocessor when the battery unit has ameasured state of charge greater than an upper threshold limit; ii) anunder-voltage output that provides an under-voltage signal to saidmicroprocessor when the battery unit has a measured state of charge lessthan a lower threshold limit; and iii) a current flow output thatprovides a current signal of current flow direction into or out of saidbattery to said microprocessor; e) an automatic battery control circuitcoupled to the battery management system, the microprocessor and thebattery unit and comprising: i) a relay comprising: a single relaycontactor extending from an input side to an output side; a transistor;and ii) a parallel resistor configured in parallel with the relaycontactor from said input side to said output side; iii) a dischargeoptocoupler coupled between the automatic battery control circuit andthe microprocessor; iv) a charge optocoupler coupled between theautomatic battery control circuit and the microprocessor; v) adifference amplifier that senses a relay potential that is a voltagepotential across the parallel resistor; wherein with the relay contactoropen, a reduction in an output side voltage of the output side isindicated by the discharge optocoupler to the microprocessor, and whenthe battery is above a threshold discharge limit, the relay contactor isclosed by said transistor and the battery unit is connected to a loadand place the automatic battery control system in a discharge mode; andwherein with the relay contactor open, an increase in the output sidevoltage of the output side is indicated by the charge optocoupler to themicroprocessor, and when the battery is below a threshold charge limit,the relay contactor is closed by said transistor to connect the batteryunit to the charging power source to place the automatic battery controlsystem in a charge mode wherein when in said discharge mode and when nounder-voltage signal is received by the microprocessor from theunder-voltage output the relay contactor remains closed and the relaypotential will be substantially zero, and the output of the dischargeoptocoupler will turn off preventing said over-voltage signal fromcausing the relay to be opened; wherein the relay will remain closed aslong as the current flow output provides a current signal of a currentflowing to the load; and wherein when said current signal of a currentflowing to the load from the battery unit stops, the microprocessor willopen the relay contactor thereby isolating the battery unit from theload; wherein when in said charge mode and when no over-voltage signalis received by the microprocessor from the over-voltage output, therelay contactor remains closed and the relay potential will besubstantially zero, and the output of charge optocoupler will turn offpreventing any under-voltage signals from causing the relay to beopened; and wherein the relay will remain closed as long as the currentflow output provides a current signal of a current flowing to thebattery unit; and wherein when said current signal of a current flowingto the battery unit stops, the microprocessor will open the relaycontactor thereby isolating the battery unit from the charging powersource.
 15. The automatic rechargeable battery control module of claim14, wherein the microprocessor opens the relay contactor when thebattery unit drops below the lower threshold limit.
 16. The automaticrechargeable battery control module of claim 14, wherein themicroprocessor opens the relay contactor when the battery is above theupper threshold limit.
 17. The automatic rechargeable battery controlmodule of claim 1, wherein the plurality of rechargeable batteriesproduce an electrical power at 48V.
 18. The automatic rechargeablebattery control module of claim 1, wherein the plurality of rechargeablebatteries produce at least 8 kW-hours of electrical power.
 19. Theautomatic rechargeable battery control module of claim 1, comprising afirst automatic rechargeable battery control module coupled with asecond automatic rechargeable battery control module to provide acombined power through the singe power connector.